LOW GRADE WHU POTENTIAL- TEXTILE SECTOR

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LOW GRADE WHU POTENTIAL- TEXTILE SECTOR
Partnership to Advance Clean Energy-Deployment
(PACE-D)Technical Assistance Program
12-Aug-14
R Rajmohan
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CONTENTS

• Process Flow
• Sources of Low Grade Waste Heat
• Overall Potential
• WHU Solutions
• Case Studies

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Textile Processing Illustrative for Cotton
Prints
Process
Utilities
Boiler
Thermopac
Air compressors
Source Cluster Manual Pali Textile Cluster BEE
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Textile Processing Pali Textile cluster- Quick
overview
Sl No Item Target Efficiency
1 Sources of Energy Electricity from Grid Pet Coke
2 Energy Use pattern Pet Coke 5 to 7 TPD (Power process) 1 to 1.5 TPD (Small Units)
3 Energy Use pattern- Electricity Power Process 3000 kWh/Day Only printing 160-500 kWh/Day
4 Specific energy consumption ( Processing of polyester Printing) Electricity 1.2 kWh/Kg Thermal 15000 Kcals/Kg
Source Cluster Manual Pali Textile Cluster BEE
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Sources of Waste Heat
Fuel Steam (LP) 3 bar
Boiler
Flue gas Blow Down
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Low Grade WH Overall Potential
Effluents Quantity 3000 Kg/Cycle Temperature 70
Deg C WHR potential 120000 Kcals/Cycle
Jiggering Swing Steam Reject condensate 120
Kg/Hr Temperature 70 Deg C WHR potential 6300
Kcals/Cycle
Dyeing _at_ 140 Deg C Reject effluent 5000
Kg/Hr Temperature 100 Deg C WHR potential
408000 Kcals/Cycle
Stretching _at_ 120 Deg C Reject Effluent 123
Kg/Hr Temperature 100 Deg C WHR potential 1230
Kcals/Cycle
WHU- Overall potential 0.323 Kg of Fuel/Kg of
Cloth Annual fuel savings 93 MT/Year Cost
savings 11.2 Lac Rs/Year
Drying Jiggering Steam Reject Effluent 200
Kg/Hr Temperature 70 Deg C WHR potential 12000
Kcals/Cycle
Drying Jiggering water Reject condensate 3500
Kg/Hr Temperature 70 Deg C WHR potential
210000 Kcals/Cycle
Mill producing 37 Kg of cloth/Hr
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Low Grade WHU Technologies Waste heat recovery
from Boiler Flue gases - Economizer

• Waste heat recovery device
• Usually used in boilers to recover waste heat
  from flue gases.
• Recovered heat is used to pre-heat feed water to
  boiler
• Useful where water feeding to boiler is continuous

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Low Grade WHU Technologies Waste heat recovery
from Boiler/Thermopac Flue gases Air Preheater

• Waste heat recovery device
• Usually used in boilers/Furnaces to recover waste
  heat from flue gases.
• Recovered heat is used to pre-heat combustion air
  to boiler/Furnace
• Useful where Economizer exists already

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Low Grade WHU Technologies Waste heat recovery
from Boiler Flue gases Water Preheater (ST
heat exchanger)

• Waste heat recovery device
• Usually used in boilers to recover waste heat
  from flue gases.
• Recovered heat is used to pre-heat boiler feed
  water
• Useful when the feed water flow to the boiler is
  not continuous

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Low Grade WHU Technologies Waste heat recovery
from Boiler Flue gases Water Preheater- Heat
pipe heat exchanger

• Waste heat recovery device
• Usually used in boilers to recover waste heat
  from flue gases.
• Recovered heat is used to pre-heat feed water to
  boiler
• Useful to recover heat where Delta T is lower

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Low Grade WHU Technologies WHR from Boiler Blow
Down Flash Steam Recovery Heat recovery from
BD condensate

• Flash steam recovery from Boiler blow down
• Heat recovery from the condensate of the blow
  down
• Recovered heat is used to pre-heat Boiler feed
  water/ other hot water requirements

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Low Grade WHU Technologies Condensate Recovery

• Condensate recovery device
• No mechanical pumping
• Recovered condensate is used as boiler feed water
• Savings of both water and heat

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Low Grade WHU Technologies Heat Recovery from
Hot effluents

• Waste heat recovery device
• Used to recover heat from process effluents

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Low Grade WHU Technologies Heat Recovery from
Hot Vapours

• Hot vapors from sources like Stenters are the
  heat source
• Used to either generate hot water or to heat the
  fresh air to the source equipments

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CASE STUDY 1 Waste heat recovery system in
Boiler
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CASE STUDY 2 Waste heat recovery system in
Thermopac
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CASE STUDY 3 Waste heat recovery Boiler
Blowdown
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CASE STUDY 4 Waste heat recovery- Jet Dyeing
Machine
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CASE STUDY 5 PHE Heat Recovery from Jet
Dyeing Machine (Sameer Synthetics)
Temp. of water drained 85oC Proposal Collect
hot water and use for pre-heating cold water
stream used for process
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CASE STUDY 2 Cost Benefit Analysis

Number of Machines in Operation 9
Quantity of Water Drained/Batch/Machine 400 l
Number of batches/day/machine 10
Water temperature at outlet of machine 80oC
Expected temperature of effluent at outlet of PHE 38oC
Expected energy savings 1,512,000 kCal/day
Equivalent Fuel Savings 189 kg/day
Equivalent Cost Savings 6.8Lakh Rs/year
Investment 4 Lakh Rs
Simple Payback Period 7 Months